Container and method of making the same



Aug. 19, 1941. .G. A. MOORE CONTAINER AND METHOD-OF MAKING THE SAME Fiied Sept. "18, 1956 l 5 Sheets-Sheet 1 a a m m a 2 0 m mm Wm- Wm MTH/ 3 M AU 4 m W n E Y. ll m m m/ W F rm a b 7 a T fl M Aug. 19, 1941. G. A. MOORE 2,252,779

CONTAINER AND METHOD OF MAKING THE SAME Filed Sept. 18, 1936 3 Sheets-Sheet 2 V Has. 4 l m 46 .6 INVENTOR 28 l/ 660%! AfiLl/VG'fO/IMOOAE ATTORNEY Aug. 19, 1941. MOORE 2,252,779

CONTAINER AND METHOD OF MAKING THE SAME Filed Sept. 18, 1956 3 Sheets-Sheet 3 I 1mm ATTORNEY INVENTOR MEIRl/IYGTGV MOORE Patented Aiig. 19, 1 941 CONTAINER AND METHOD OF MAKING THE SAME George Arlington Moore, Louisville, Ky., asslgnor Humoco Corporation, Lo i i l Ky a P ration of Delaware 1 Application September 18, 1936, Serial No. 101,406

Claims. (01. 229-30) This invention relates to containers, and more particularly to containers comprising fibrous materials, and to a method for making the same.

Containers constituted by deformed blanks, having the marginal portions drawn into flanged relation with the central portions thereof to form seamless side walls have been heretofore provided. Containers of this type are more rigid and durable, and may be more readily and inexpensively manufactured than folded containers, but, due to the fact that in the drawing operation the marginal material of the blank must be compressed at the corners of angular containers, for example, and entirely around the periphery of containers having curved walls, and to the fact that the extent of said compression varies directly as the height of the drawn flange or side walls, there is a limit to the height to which a flange can be successfully drawn. Beyond a certain height, depending on the particular material employed, the compression and consequent density of the fibers becomes so great that brittleness and fracture result, or wrinkling and pleating of the material occurs, thereby producing weakness. It will thus be seen that only comparatively shallow containers have been heretofore produced from blanks by subjecting the latter to a drawing operation.

In making deep containers from blanks by folding a plurality of tongues or tabs thereof in various ways known to the art, it is extremely diflicult to provide comers at the top and bottom of the container which are leakproof, and it is substantially impossible to provide a container of this type which is impervious to air and moisture.

It is accordingly an object of the present invention to provide a novel container or receptacle which is deeper than containers can be successfully drawn and yet one which possesses the advantages of and is substantially as strong as a container having seamless drawn side walls.

Another object of the invention is to provide a novel container and method of producing the same, the side walls of said container having,

seams which extend for. only a portion of the depth of the same.

A further object is to provide a container having a closure supported thereby and sealed therein in a novel manner.

A still further object is to provide a novel deep tures of the invention will more fully appear from the following detailed description, when the same is read in connection with the accompanying drawings. It is to be expressly understood, however, that the drawings are for the purpose I of illustration only and are not intended to de container which may be formed from a single blank and which is imperviousto air and moisture.

"The above and further objects and novel feafine the limits of the invention, reference being primarily had for this latter purpose to the appended claims.

In the drawings, wherein like reference characters refer to like parts through the several views:

Fig. 1 shows a blank from which one form of container embodying the present invention may be produced;

Fig. 2 is an isometric view, partially in section, of a container formed from said blank;

Fig. 3 is a side elevation; partly in section and with parts broken away, illustrating one means and method of securing a closure in said container;

Fig. 4 is a detailed sectional view on an enlarged scale, the section being taken on line 44 of Fig. 2;

Fig. 5 is a side elevation, partly in section and with parts broken away, illustrating the initial step in the formation of the container body;

Fig. -6 is an isometric view showing the container only partially completed;

Fig. 7 is a view similar to Fig. 6, showingthe position of the die members at the completion of said body;

Fig. 8 is an isometric view, partly in section and with parts broken away, of a female die which may be employed in forming the container;

Fig. 9 shows a blank which may be employed in forming a second embodiment of the invention;

Fig, 10 is a side elevation, partly in section and with parts broken away, of means for deforming a section of said blank to form the cover of the container;

- Fig. 11 is an isometric view, partly in section and with parts broken away, of a completed container';

Fig; 12 is a sectional detailed view, on an enlarged scale, of means for sealing the top closure or cover in the mouth of the container body; and

Fig. 13 is an enlarged detailed view, partly in section and with parts broken away, illustrating the manner in which the container of the present invention may be readily opened.

One embodiment of the invention and a method and means for producing the same are illustrated in Figs. 1 to-8, inclusive, the container being shown, by way of example, as having a substantially rectangular shape, both in horizontal and in vertical cross section, the comers thereof being preferably slightly arcuate. The blank from which the container is formed may be made of fibrous or other suitable materials, and may be of a single thickness, or laminated and constituted of one or a plurality of suitable materials, such as fiber board and foil or sheet acetate. The blank is first cut to the desired shape and thereafter subjected to the action of cooperating die members, whereby the lower portion of the side walls of the receptacle which is formed are seamless and the upper portions thereof are folded and overlap at the comers, the comer seams of said folded portions being progressively welded by heat and high pressure as the folding operation progresses.

In the form shown in Fig. 1, the blank comprises a substantially rectangular central portion l5, which is preferablyof substantially the same length and width as the desired horizontal cross section of the container to be constructed therefrom, a portion of the blank immediately surrounding said central portion and constituting a margin of the latter being adapted to be drawn into flanged relation with said central portion, in a manner to appear hereafter, to

form the lower or seamless part of the side walls, ofa container or receptacle. Integral with and extending laterally from two opposed sides of said rectangular portion l5 are a pair of flaps or sections l6, which are of substantially the same width as the desired receptacle and may be of any desired length, depending upon the depth of the receptacle required. A second pair of flaps or sections II, also integral with said central portion and extending laterally therefrom, have a slightly greater width than the dimensionsof the sides of the receptacle which the same are adapted to form, the width of said sections gradually increasing from the inner to the outer ends of the same.

For a purpose to more fully appear hereafter, the surfaces of the above-described blank may be coated with a thin, dry fllm of moisture-proof thermoplastic lacquer having potential adhesive qualities or, if desired, said lacquer need be applied only'to' a marginal strip I 1a of the inner surface of flap I! as indicated in the drawings. Some lacquer is also preferably applied to strips [6a of the outer surface of flaps l6 and to marginal strips I61) and "b of the inner surfaces of flaps l6 and I 1, respectively; Said lacquer film is preferably adapted to be activated or rendered tacky by a solvent, by heat, or both, and thereby rendered effective to bind engaging surfaces of the blank together, If heat alone is used as an activating agent, the lacquer should be of such composition as to be rendered tacky only at temperatures considerably in excess of usual room temperatures, for example, 125 to 140 One suitable lacquer which fulfills the'above requirements and which may be readily and quickly applied to the blank in the desired manner is composed of about 65% of such ester solvents as ethyl acetate, butyl acetate, or the like, and such hydro-carbons as toluol, and about 35 per cent of solids which can be readily activated by solvents as well as heat. The solids content is composed of about 25 per cent of low viscosity nitro-cotton, 60 per cent of resins, and

about 15 per cent of a plasticizer such as diroom temperatures and under normal conditions of humidity, and may be readily and quickly applied to the entire surface or any localized portion of the surface of the blank, the same being adapted to dry quickly after each activation thereof. Contact temperatures for forming seals along the desired lines must accordingly be in excess of about 150 F., the excess being dependent upon the speed of operation and the thermal conductivity of the material constituting the blank. Under normal conditions, the lacquer is firm but sufliciently flexible and elastic so thatthe same will not crack or flake or become susceptible to penetration by air and moisture when. the blank is drawn, folded and sealed in the novel manner to appear hereafter.

In order to form a receptacle or container from the above-described blank, the latter is subjected to the action of cooperating male and female die members, one suitable form of which is illustrated in Figs. 5, '7, and 8 as comprising a female die l8, a yieldingly supported builer die l9 which is operable in a substantially rectangular opening 18a in said female die, and a reciprocable male die assembly which includes a drawing die member 20 that is adapted to be reciprocated in female die l8 by any suitable or well-known means (not shown) and is formed to cooperate with buffer die I9 in a manner to appear hereafter. Said male die assembly also includes a die member 2| which fits into a recess in the lower face of die member 20 and is carried by a, movable rod 22 on which member 20 is mounted to slide. Die member 2| is thus adapted to be moved relative to die 20 and constitutes a stripper for removing formed container bodies from the latter die. Surrounding die 20 and movable relative thereto is a third die member 23, the lower face 23a of which curves upwardly and outwardly from the outer walls of die 20 and is adapted to enact with rounded corners lab at the upper end of opening 18a in female die l8 for forming the flared mouth of the container and a seat for a closure member therefor. Die member 23 may also cooperate with die 2| for stripping the formed container body from die 20. The dimensions of dies 20 and I9 in horizontal cross section are substantially equal to the corresponding inner and outer dimensions, respectively, of the receptacle or container which it is desired to form. If desired, female die l8 may be constituted by a plurality of segments, whereby said die might be slightly expanded after the formation of body l6, l1, construction lines I (Fig. 8) denoting the surface junctures of said segments.

Preferably, the lower face of male die 20, 2| I of the container. Embossing the blank in this manner enhances the rigidity of the container and strengthens the bottom thereof to obviate bulging or bowing of the same.

In the formation of a container by the coaction of the above-described die members, the blank is placed on the upper surface of female die It with central portion i thereof centered over opening l3 and, hence, over the upper face of buffer die I! which is normally held by suitable means, such as by a spring or cam (not shown), in substantially the position illustrated in Fig. 5. Male die 20, 2| is then moved downwardly into contact with said blank by any suitable power means (not shown). Power means suitable for this purp se are old and well known in the art and it is accordingly believed to be unnecessary to illustrate and describe the same in detail herein, such means, per se, constituting no part of the present invention. Further downward movement of male die 20, 2| is yleldingly resisted by die IS with suflicient pressure to permit the irregular faces of said dies to mesh with each other and hnce cause an external peripheral bead 29 and an internal rib 29 to be embossed in central portion I5 of the blank, thereby forming the bottom of the container.

After the blank is thus embossed, buffer die l9 yields to continue movement of die 20, 2| and moves downwardly in response to the pressure exerted by the latter, thereby causing the margin of central portion l5 of the blank, 1. e., a strip surrounding that portion of the blankenclosed by construction line 30, to be drawn into flanged relation with said central portion to form a smooth, seamless peripheral flange which constitutes the lower part of the side walls of the receptacle or container. The entire lower edge of the container is thus rendered strong and absolutely leak-proof, particularly at the corners.

Furthermore, the corners will not be made subject to leakage by deformations resulting from handling, such as when the container is dropped, as will the comers which are formed on prior containers by merely folding a blank into container form.

As soon as this drawing operation is completed, or at any time during said drawing operation, side flaps l6 are folded up into engagement or near engagement with the sides of die 20 by a pair of arms or fingers 2|. Thus, as die 20, 2| moves downwardly and draws flaps l6 and I1 into female die' l8, the tapered lacquer-coated margins llaof flaps I! are caused, by the rounded corners of dies [8 and 20, to progressively curl or bend around the corners of the latter die and overlap the marginal strips l6a of flaps l6 which may also be lacquer coated. Margins lfia and I la are thus drawn into die i8 and progressively pressed into intimate contact with each other substantially as shown in Fig. 4.

For the purpose of progressively securing the overlapped portions of flaps l6 and I! together as the same are drawn into die Hi, the latter die is heated by any suitablemeans, such as by electric heating coils or by circulating steam through a passage 32 in the die. Heat from the walls of die I8 is conducted through the material of the blank to the lacquer films on "margins Ilia and Ho and said films are thus activated and rendered sufliciently tacky to be pressed, by the pressure of the dies, into the interstices of the fibrous material to thereby substantiallyweld the engaging surfaces together. Strong moisture-proof joints are thus provided at the corners to complete the upper portion of the walls of the container, said walls being of substantially uniform thickness throughout. It will thus be apparent that a container of substantially any depth and having the lower wall portions thereof continuous or seamless may be readily and quickly formed from a blank comprising less material than has been heretofore used in making a container of similar size and capacity.

Preferably, die 20 is moved downwardly until all but the upper margins of flaps l6 and i1 have been drawn into female die l8. The movement of die 20 is then stopped while die 23 continues its downward movement, the knife-like lower edge of the face 23a of said latter die being adapted to move between said flaps and the walls of die 20 and, hence, to press the lacquer coated margins I61) and Nb outwardly into contact with rounded comers l8b of the opening in die l8. Said margins are thus flared outwardly to form a curved peripheral flange about the mouth of the container.

, Arcuate flange I 3b, "b not onlyincreases the strength and rigidity of the container but it also serves as a seat for a closure member whereby the latter may be novelly secured in the container body to render the container impervious to air and moisture and yet be readily removable therefrom without in any way damaging the container walls. In securing the cover or closure in place, body l6, I1 is inserted in a female die 33 (Fig. 3) wherein said body may be supported by the engagement of flange Nib, ill) with the upper rounded corners of the die. A cover 34, embossed and formed from a blank by coacting die members of substantially the same character as those shownin Fig. 10 and to be hereinafter described is then inserted in the flared mouth of body ll, I I, the arcuate marginal portion 35 of the closure engaging lacquer coated flange ltb, llb. Pressure is then applied to the engaging portions of the body and cover by a suitably shaped die member 36 and heat is simultaneously supplied to said engaging portions by electric heating elements 31 and 38 provided in dies 33 and 36, re-

spectively, whereby the lacquer fllm applied to strips lBb and Ill) is activated-and pressed into the interstices of the engaging surfaces. Cover 34 is thus substantially welded to the container body, the joint formed therebetween being impervious to both air and moisture.

Cover 34 is preferably provided with a tab 39 on one side thereof for use in opening the container. When tab 39 is pulled back toward the center of the container, closure 34 will be severed from the walls of body i6, i! at the joint formed therebetween, in the manner above described, without danger of injury to the walls of the body itself (Fig. 13).

In the embodiment of the invention illustrated in Figs. 9 to 12, inclusive, the blank employed is identical with that of Fig. 1, except that a flap 34, 39', from which the container cover may be formed, is integral with and constitutes an extension of one of the flaps l6. Prior to the drawing, folding, and sealing, of the container body from portions l5, I6, and I1 of the blank in the same manner as above described, flap 34', 39 is subjected to the action of die members 40, 4| and 42, 43, (Fig. 10) the latter of which are adapted to be moved toward and away from the former by any suitable means (not shown). The faces of said die members have complementary ribs and grooves therein for forming a strengthening rib in the closure and the peripheral arcuate margin 35' thereof. Die 43 is preferably yieldingly held against the blank during the emthe cover thus formed from stationary die 40.

Body I1, I1 is then formed by coacting die members of the character shown in Fig. 5 and .in the same manner above described, and cover 34' is thereafter folded to the position seen in Fig. 11, the arcuate marginal portion 35' thereof being adapted to engage the lacquer coated margin I6b, l'lb at the mouth of the container body. That portion of the blank which connects flap l6 and flap 34' serves as a hinge for pivoting said cover. Thereafter, the cover or closure is sealed in place in the same manner above pointed out in connection with the application of cover 34, or dies 44 and 45 (Fig. 12) which are similar to dies 33 and 36 may be employed in a like manner. In the form shown, die 44 may be steam heated and die 45 may be heated by'nieans of an electrical heating element 46 for the purpose of activating the adhesive coating between the engaging surfaces of the closure and the container body. It will be readily seen from Figs. 3 and 12 that by supporting container body I6, ll externally in the manner illustrated a comparatively great pressure may be exerted by dies 36 and 45 for the purpose of insuring an impervious joint between the closure and said body without the slightest danger of crushing the container or the contents thereof. Although the joint thus formed is impervious, the same may be readily severed, in the manner shown in Fig. 13, by proper manipulation of tab 39'.

There is thus provided a novel container which has a portion of the wall thereof drawn and seamless while the remainder of the wall is constituted by flaps that are folded and drawn into position and imperviously sealed at the comers of the container in a novel manner. A container which is deeperthan containers can be successfully drawn with smooth walls and which has substantially the same advantageous features as drawn containers that are free from weakening pleats and gathers of material is accordingly provided. It will be noted that any desirable printed matter, such as advertising and information, may

a moisture-resistant lacquer in the same manher that the body portion maybe coated therewith and no'lacquer need be provided on strips lBb-and l'lb (Fig. 2) if it is not desired to secure a closure in the body. Various other changes may be'made in the size, shape, and design of the containers shown, as well as in the materials employed, without departing from the spirit and scope of the invention, as will now be apparent to those skilled in the art. .For a definition of the limits of the invention, reference will be had primarily to the appended claims.

What is claimed is:

1. A container constituted by a blank comprising fibrous materials and having a central portion, a marginal strip surrounding the latter being drawn to form a seamless flange about said central portion, and laterally extending flaps integral with said flange and turnedupwardly to bring the margins of adjacent edges thereof into overlapping relation, said overlapping margins being joined together by an adhesive to complete the side walls of the container.

2. A fibrous container having one end thereof open, the same being constituted by a blank having a central portion, a marginal strip surrounding said portionbeing drawn into flanged relation with the center thereof, and flaps integral with said margin, said flaps being folded upwardly and having the adjacent edges thereof joined by an adhesive, and the upper margins of said flaps being turned outwardly to form a seat for a closure member.

3. A container constituted by a blank including a rectangular-like central portion, a side flap extending from each side of said central portion, said side flaps being folded into flanged relation with said central portion and having the overlapping side margins thereof adhesively secured and the upper margins thereof flared outwardly, and

a formed cover flap integral with one of said side flaps and folded into engagement with said outwardly turned margins of said side flaps, the engaging surfaces of said cover and side flaps being adhesively secured to form a closed container.

4. A container constituted by a blank having a substantially rectangular central portion and Additionally, a novel method of I portions extending laterally from the sides of said central portion, a margin of said central portion and said laterally extending portions being drawn into flanged relation with the remainder of said central portion, themargins of two of said laterally extending portions overlappingadjacent edges of the other two of said laterally extending portions and adhesively secured thereto and the upper margins of said laterally extending portions being turned outwardly, and.

a closure having a portions contoured to engage said outwardly turned margin and adhesively secured thereto.

5. A container constituted by a blank including a substantially rectangular central portion, a side flap extending at right angles from each side of said central portion, the margin of said central portion and said side flaps beingdrawn into flanged relation with the center of said central portion, the side margins of adjacent flaps being adhesively secured together, and a cover flap integral with one of said side flaps and hinged into engagement with the upper margins of said side flaps, said cover flap being adhesively secured to said side flaps entirely around the mouth of the container.

' GEORGE ARLINGTON MOORE. 

